Lehr Precision, Inc.

General Electric Company

Norbert A Bruns

John S Reynolds

Edward C Bruns

Richard F Fussner

Thomas Howard Chamberlain

An ECM apparatus includes a fluted cathode tool for being driven through a tubular workpiece for electrochemically forming internal flutes therein. The cathode tool is sealed at one end for isolating electrolyte over the flutes thereof to seal against flow of the electrolyte past the tool and into the finished fluted bore.

Fluted electrochemical machining

A slave assembly is provided to protect an anodic workpiece joined to a shuttle from stray electrochemical machining. The assembly includes a slave having a support flange joined integrally with a sacrificial flange positionable adjacent to the workpiece for being electrochemically machined along with the workpiece to prevent stray electrochemical machining between the sacrificial flange and the workpiece. A retainer is positionable on the slave support flange to clamp the slave to the shuttle.

ECM slave assembly

An apparatus for electrochemically machining a workpiece having first and second platforms and an airfoil extending transversely therebetween includes a first cathode trio having a center cathode disposed between first and second cathodes. The center cathode is configured for electrochemically machining a first side of the airfoil, and the first and second cathodes are configured for electrochemically machining at least the first and second platforms adjacent to the airfoil first side. The first and second cathodes are movable relative to the center cathode so that they move away from each other and toward the opposing platforms during machining. A second cathode trio is provided for electrochemically machining the airfoil second side. The apparatus is effective for practicing an improved method of electrochemically machining the workpiece by moving the first and second cathode trios toward the workpiece first and second side, and moving the first and second cathodes of each of the cathode trios toward the airfoil first and second sides and toward the first and second platforms relative to movement of the center cathodes thereof. The resulting product formed by the method requires little or no benching of the airfoil and platforms.

Multi-cathode ECM apparatus, method, and product therefrom

A machine for electrochemically machining (ECM) a workpiece having a stacking axis and first and second opposite sides includes a pair of cathode tools. The first and second tools have first and second longitudinal axes, respectively, disposed substantially perpendicularly to the workpiece stacking axis. The first and second tools also include the first and second transverse axes, respectively, disposed perpendicularly to the first and second longitudinal axes, respectively, and substantially parallel to the workpiece stacking axis. The machine is effective for practicing an improved method of moving the first and second tools along the first and second longitudinal axes and along the first and second transverse axes, respectively, toward the workpiece for the electrochemical machining thereof. By moving the respective cathode tools along both longitudinal and transverse axes, a selectively variable resultant feedrate direction is obtained which is inclined relative to the workpiece stacking axis.

Four-axis ECM machine and method of operation

In accordance with a preferred, exemplary embodiment of the invention, an apparatus for forming a blisk from a workpiece is disclosed. The workpiece includes a blank having oppositely facing first and second faces defined by a radially inner base, a radially outer top, a first edge, and a second edge. The apparatus includes first and second complementary electrodes positionable about the workpiece blank. Each electrode has a support portion and a working portion. Means for channeling electrolyte from an inlet to an outlet defined between the electrodes, and means for sealing the working portions to prevent leakage are disclosed. Electrolyte is channeled between the first and second edges to finally electrochemically machine an airfoil in a single operation from the blank.

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Cincinnati, OH, United States of America

Norbert A Bruns